Adjust SUZUKI SWIFT 2006 2.G Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine 6C-42 Power Assisted Steering System:
2) Connect tie-rod end to knuckle. Tighten tie-rod end nut (1) to spec ified torque.
3) Bend new split pin (2).
NOTE
After tightening tie-rod end nut to specified
torque, match next first slot of nut with hole
of tie-rod end for insertion of split pin
(rotation angle 60 ° max).

Tightening torque
Tie-rod end nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)
4) Inspect for proper toe re ferring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
5) After confirming proper toe, tighten tie-rod end lock nut to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5
lb-ft)
6) Tighten wheel nuts to specified torque and lower hoist.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tie-Rod End InspectionS7RS0B6306004
• Inspect for play in ball joint.
• Inspect for play in rack end ball joint. In either case, if found defective, replace.
Steering Shaft Joint On-Vehicle InspectionS7RS0B6306005
Check shaft joint for wear, breakage and any other
damage and replace if any defect exists.
Steering Gear Case Assembly Removal and
Installation
S7RS0B6306006
Removal
CAUTION!
Be sure to set front wheels (tires) in straight
direction and remove ignition key from key
cylinder before performing the following
steps; otherwise, contact coil of air bag
system may get damaged.

1) Remove front suspension frame with steering gear case assembly referrin g to “Front Suspension
Frame, Stabilizer Bar and/ or Bushings Removal and
Installation in Section 2B”.
2) Remove steering gear case mounting No.3 bolts (4), No.1 bolts (1), No.2 bolts (2) and gear case bracket,
then remove gear case (3) from front suspension
frame (5).
2 1,(a)
I7RS0A630017-01
I3RM0A630030-01
I4RS0A630043-01
I4RS0B630012-01
25
3
14
I6RS0C630018-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-43
Installation1) Mount steering gear case (1) to front suspension frame (2) and tighten gear case mounting No.1 bolts
(3), No.2 bolts (4) and No .3 bolts (5) to specified
torque.
Tightening torque
Steering gear case mounting No.1 bolt (a): 55
N·m (5.5 kgf-m, 40.0 lb-ft)
Steering gear case mounting No.2 bolt (b): 55
N·m (5.5 kgf-m, 40.0 lb-ft)
Steering gear case mounting No.3 bolt (c): 40
N·m (4.0 kgf-m, 29.0 lb-ft)
2) Install earth cable (6) as shown in figure. Tightening torque
Earth cable bolt (d): 4.5 N·m (0.45 kgf-m, 3.5 lb-
ft)
3) Install grommet (1) whose projection (2) orients vehicle forward.
4) Install front suspension frame with steering gear case assembly referring to “Front Suspension
Frame, Stabilizer Bar and/or Bushings Removal and
Installation in Section 2B”.Steering Rack Boot InspectionS7RS0B6306007
Hoist vehicle.
Inspect each boot for tear. A torn boot allows entry of
dust and water which can cause wear to steering rack
and pinion to produce noise as well as rust to result in
malfunction of steering system.
Even if boot tear is small, replace with new one.
Also, check each boot for dent. If there is a dent, keep
boot in most compressed st ate for some seconds to
correct dent.
Boots should be visually inspected for any damage, dent
and tear during every periodical inspection at specified
intervals and whenever vehicle is hoisted for any other
purpose.
Tie-Rod / Rack Boot Removal and InstallationS7RS0B6306008
Removal
1) Remove steering gear case assembly referring to
“Steering Gear Case Assembly Removal and
Installation”.
2) For ease of adjustment after installation, make marking (1) of tie-rod end lock nut position of tie-rod
thread.
3) Loosen tie-rod end lock nut and remove tie-rod end.
4) Remove boot band (2) and clip (1).
5) Remove boot from tie-rod.
F: Vehicle forward
1 2
3, (a) 4, (b)
6, (d)
5, (c)
I6RS0C630019-02
12
F
I6RS0C630020-01
I2RH01630012-01
I4RS0A630044-01
IYSQ01630034-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-45
8) Install steering gear case assembly referring to “Steering Gear Case Assembly Removal and
Installation”.
Steering Rack Plunger Removal and InstallationS7RS0B6306009
Removal
1) Remove gear case assembly referring to “Steering
Gear Case Assembly Removal and Installation”.
2) Loosen lock nut (1) with holding damper screw (2).
3) Remove lock nut (1), rack damper screw (2), rack plunger spring (3) and rack plunger (4).
Installation 1) Apply grease lightly to sliding part of plunger (1) against rack.
“A”: Grease 99000–25050 (SUZUKI Super
Grease E)
2) Install plunger and spring (2) as shown.
3) Apply thread lock cement to rack damper screw (3)
and tighten them as follows.
a) Tighten damper screw to 25 N ⋅m (2.5 kgf-m, 18.0
lb-ft).
b) Loosen damper screw until 180 °.
c) Retighten damper screw to 3.9 N ⋅m (0.39 kgf-m,
3.0 lb-ft).
d) After tightening rack damper screw to specified torque, turn it back by 7 ± 3°.
“B”: Thread lock cement 99000–32110
(Thread Lock Cement Super 1322)
Tightening torque
Rack damper screw (a): Tighten 25 N ⋅m (2.5
kgf-m, 18.0 lb-ft) and loosen 180° and then
tighten 3.9 N ⋅m (0.39 kgf-m, 3.0 lb-ft) and turn
it back by 7 ± 3° by the specified procedure. 4) Pinion rotation torque should be checked with rack
position centered.
Also, check if rack as a whole moves smoothly.
Special tool
(A): 09944–18310
Tightening torque
Rotation torquer of pinion (a): 2.0 N·m (0.2 kgf-
m, 1.5 lb-ft)
5) After adjustment, tighten lo ck nut to specified torque
with holding damper screw at the position.
Tightening torque
Rack damper screw lock nut (a): 64 N·m (6.4
kgf-m, 46.5 lb-ft)
6) Install gear case assembly referring to “Steering Gear Case Assembly Re moval and Installation”.
Steering Rack Plunger InspectionS7RS0B6306010
• Inspect rack plunger (1) for wear or damage.
• Inspect rack plunger spring (2) for deterioration.
I4RS0A630045-01
I4RS0A630046-01
I3RM0A630055-02
I4RS0A630047-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 7- i
7
Section 7
CONTENTS
HVAC
Precautions ................................................. 7-1
Precautions............................................................. 7-1
Precautions on HVAC ........................................... 7-1
Heater and Ventilation.... ......................... 7A-1
General Description ............................................. 7A-1
Heater and Ventilation Construction ................... 7A-1
Schematic and Routing Diagram ........................ 7A-2 Heater and Ventilation Wiring Circuit Diagram .... 7A-2
Diagnostic Information and Procedures ............ 7A-3 Heater and Ventilation Symptom Diagnosis........ 7A-3
Repair Instructions .............................................. 7A-4 HVAC Unit Components ..................................... 7A-4
HVAC Unit Removal and Installation .................. 7A-4
Blower Motor Removal and Installation............... 7A-4
Blower Motor Inspection ..................................... 7A-4
Blower Motor Resistor Removal and Installation ......................................................... 7A-5
Blower Motor Resistor Inspection ....................... 7A-5
Blower Motor Relay Inspection ........................... 7A-6
HVAC Control Unit Components ......................... 7A-6
HVAC Control Unit Remova l and Installation ...... 7A-7
Blower Speed Selector In spection ...................... 7A-9
Air Intake Selector Inspec tion ............................. 7A-9
Air Intake Control Actuator Removal and Installation ......................................................... 7A-9
Air Intake Control Actuator Inspection .............. 7A-10
Center Ventilation Louver Removal and Installation ....................................................... 7A-10
Side Ventilation Louver Removal and Installation ....................................................... 7A-11
HVAC Air Filter Removal and Installation (If Equipped)........................................................ 7A-12
HVAC Air Filter Inspection (If Equipped) ........... 7A-12
Air Conditioning System... ...................... 7B-1
Manual Type ............................................................ 7B-1
Precautions........................................................... 7B-1A/C System Caution ............................................ 7B-1
Precautions on Servicing A/C System ................ 7B-1
General Description ............................................. 7B-3 Refrigerant Type Identifica tion ............................ 7B-3
Sub-Cool A/C System Description ...................... 7B-4
A/C Operation Description .................................. 7B-4 Schematic and Routing Diagram ........................7B-5
Major Components of A/C System ...................... 7B-5
A/C System Wiring Diagram ............................... 7B-6
Diagnostic Information and Procedures ............7B-7 A/C System Symptom Diagnosis ........................ 7B-7
Abnormal Noise Sympto m Diagnosis of A/C
System .............................................................. 7B-9
A/C System Performance Inspection ................ 7B-10
A/C System Inspection at ECM ......................... 7B-15
Repair Instructions ........... .................................7B-16
Operation Procedure for Re frigerant Charge .... 7B-16
Condenser Assembly On-Vehicle Inspection .... 7B-21
Condenser Assembly Removal and Installation ....................................................... 7B-21
Receiver/Dryer Removal and Installation .......... 7B-22
HVAC Unit Components ................................... 7B-23
HVAC Unit Removal and In stallation ................ 7B-24
Evaporator Inspection ....................................... 7B-24
Evaporator Thermistor (Evaporator Temperature Sensor) Removal and
Installation ....................................................... 7B-25
Evaporator Thermistor (Evaporator Temperature Sensor) Inspec tion..................... 7B-25
Expansion Valve Removal and Installation ....... 7B-26
Expansion Valve Inspection .............................. 7B-26
A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................. 7B-26
A/C Refrigerant Pressu re Sensor Removal
and Installation ................................................ 7B-26
A/C Switch Inspection ....................................... 7B-27
Compressor Relay Inspection ........................... 7B-27
Compressor Drive Belt Inspection and Adjustment ...................................................... 7B-27
Compressor Drive Belt Removal and Installation ....................................................... 7B-28
Compressor Assembly Removal and Installation ....................................................... 7B-28
Compressor Assembly Components................. 7B-29
Magnet Clutch Inspection.................................. 7B-29
Magnet Clutch Removal and Installation........... 7B-29
Relief Valve Inspection...................................... 7B-31
Relief Valve Removal and Installation............... 7B-32
Specifications .................... .................................7B-32
Tightening Torque Specifications ...................... 7B-32
Special Tools and Equipmen t ...........................7B-33

Downloaded from www.Manualslib.com manuals search engine 7-ii Table of Contents
Recommended Service Material ....................... 7B-33
Special Tool ...................................................... 7B-33
Automatic Type .................... .................................7B-34
Precautions.........................................................7B-34 A/C System Caution .......................................... 7B-34
Precautions in Diagnosing Trouble ................... 7B-34
Precautions on Servicing A/C System .............. 7B-34
General Description .......... .................................7B-34
Auto A/C System Descript ion ............................ 7B-34
HVAC Control Module Operation Description ... 7B-36
Refrigerant Type Identifica tion .......................... 7B-36
Sub-Cool A/C System Description .................... 7B-36
A/C Operation Description ................................ 7B-36
On-Board Diagnostic System Description ......... 7B-37
Schematic and Routing Diagram ......................7B-37 Major Components of A/C System .................... 7B-37
A/C System Wiring Diagra m ............................. 7B-38
Diagnostic Information and Procedures ..........7B-39 A/C System Symptom Diagnosis ...................... 7B-39
Abnormal Noise Sympto m Diagnosis of A/C
System ............................................................ 7B-42
DTC Check........................................................ 7B-42
DTC Clearance ................................................. 7B-43
DTC Table ......................................................... 7B-44
Fail-Safe Table ................. ................................. 7B-45
Scan Tool Data ................................................. 7B-46
Air Conditioning System Check......................... 7B-47
Visual Inspection ............................................... 7B-49
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction .......................... 7B-49
DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction .............. 7B-50
DTC B1504: Sunload Sensor and/or Its Circuit Malfunction ......... ................................. 7B-52
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-53
DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-55
DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction .......................... 7B-57
DTC B1514: Air Flow Co ntrol Actuator and/or
Its Circuit Malfunction ...................................... 7B-60
DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction .............................. 7B-62
DTC B1546: A/C Refrigerant Pressure Malfunction ...................................................... 7B-63
DTC B1551: Serial Communication Circuit Malfunction ...................................................... 7B-63
DTC B1552: Serial Communication Signal Malfunction ...................................................... 7B-64
DTC B1553: CAN Communication Signal Malfunction ...................................................... 7B-65
DTC B1557: Vehicle Speed Sensor Signal Malfunction ...................................................... 7B-65
DTC B1561: Engine Coolant Temperature Sensor Signal Malfunctio n .............................. 7B-66 DTC B1562: Outside Air Temperature Sensor
Signal Malfunction ........................................... 7B-66
DTC B1563: A/C Refr igerant Pressure
Sensor Signal Malfunction .............................. 7B-66
Inspection of HVAC Control Module and Its Circuit .............................................................. 7B-67
A/C System Performance Inspection ................ 7B-70
A/C System Inspection at ECM ......................... 7B-70
Repair Instructions ............ ................................7B-71
Operation Procedure for Refrigerant Charge .... 7B-71
HVAC Unit Components ................................... 7B-72
HVAC Unit Removal and In stallation ................ 7B-73
Temperature Control Actuator Removal and Installation ....................................................... 7B-73
Temperature Control Actuat or Inspection ......... 7B-73
Air Flow Control Actuator Removal and Installation ....................................................... 7B-74
Air Flow Control Actuator Inspection ................. 7B-74
Air Intake Control Actuator Removal and Installation ....................................................... 7B-75
Air Intake Control Actuator Inspection............... 7B-75
Actuator Linkage Inspection .............................. 7B-76
Blower Motor Controller Removal and Installation ....................................................... 7B-76
Blower Motor Controller Inspection ................... 7B-76
HVAC Control Module Removal and Installation ....................................................... 7B-77
Sunload Sensor Removal and Installation ........ 7B-77
Sunload Sensor Inspection ............................... 7B-77
Outside Air Temperature Sensor Removal and Installation ................................................ 7B-77
Outside Air Temperature Sensor Inspection ..... 7B-77
Inside Air Temperature Sensor Removal and Installation ....................................................... 7B-78
Inside Air Temperature Sens or Inspection ........ 7B-78
Condenser Assembly On-Vehicle Inspection .... 7B-78
Condenser Assembly Removal and Installation ....................................................... 7B-78
Receiver/Dryer Removal and Installation .......... 7B-78
Evaporator Inspection ....................................... 7B-78
Evaporator Temperature Sensor Removal and Installation ................................................ 7B-78
Evaporator Temperature Se nsor Inspection ..... 7B-78
Expansion Valve Removal an d Installation ....... 7B-78
Expansion Valve Inspection .............................. 7B-78
A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................. 7B-78
A/C Refrigerant Pressu re Sensor Removal
and Installation ................................................ 7B-78
Compressor Relay Inspection .
.......................... 7B-78
Compressor Drive Belt Inspection and Adjustment ...................................................... 7B-78
Compressor Drive Belt Removal and Installation ....................................................... 7B-79
Compressor Assembly Removal and Installation ....................................................... 7B-79
Compressor Assembly Components................. 7B-79
Magnet Clutch Removal and Installation........... 7B-79
Magnet Clutch Inspection.................................. 7B-79
Relief Valve Inspection...................................... 7B-79

Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-3
Diagnostic Information and Procedures
Heater and Ventilation Symptom DiagnosisS7RS0B7104001
ConditionPossible cause Correction / Reference Item
Blower motor does not
operate with blower
speed selector ON Fuse blown
Check related fuses, and then check for short
circuit to ground.
Blower motor relay faulty Check blower motor relay referring to “Blower
Motor Relay Inspection”.
Blower motor resistor faulty Check blower motor resistor referring to
“Blower Motor Resistor Inspection”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection”.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection”.
Wiring or grounding faulty Repair as necessary.
Incorrect temperature
output Temperature control cable broken or
bent (manual A/C) Check temperature control cable.
Temperature control lever faulty (manual
A/C) Check temperature control lever.
Incorrect installation of temperature
control cable (manual A/C) Check position and adjust it as necessary.
Temperature control door assembly
broken Repair temperature control door assembly.
Air ducts clogged Repair air ducts.
Heater core leaked or clogged Replace heater core.
Heater hoses leaked or clogged Replace heater hoses.
Thermostat faulty Check thermostat referring to “Thermostat
Inspection in Section 1F”.
Temperature control actuator faulty
(automatic A/C) Check temperature control actuator referring to
“Temperature Control Actuator Inspection in
Section 7B”.
HVAC control module faulty (automatic
A/C) Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (automatic A/
C) Repair as necessary.
Air outlet port does not
change or does not agree
with air flow selector’s
position even if air flow
selector is changed Air flow control cable broken or bent
(manual A/C)
Check air flow control cable.
Air flow control lever faulty (manual A/C) Check air flow control lever.
Incorrect installation of air flow control
cable (manual A/C) Check position and adjust it as necessary.
Air flow control door assembly broken Repair air flow control door assembly.
Air ducts leaked or clogged Repair air ducts.
Air flow control actuator faulty
(automatic A/C) Check air flow control actuator referring to “Air
Flow Control Actuator
Inspection in Section
7B”.
HVAC control module faulty (automatic
A/C) Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (automatic A/
C) Repair as necessary.
Air intake door does not
change even if air intake
mode is changed Air intake door broken
Repair air intake door.
Air intake control actuator faulty Check air intake control actuator referring to
“Air Intake Control Actuator Inspection”.
Air intake selector faulty Check air intake selector referring to “Air Intake
Selector Inspection”.
Wiring or grounding faulty Repair as necessary.

Downloaded from www.Manualslib.com manuals search engine 7A-4 Heater and Ventilation:
Repair Instructions
HVAC Unit ComponentsS7RS0B7106001
For manual type A/C, refer to “HVAC Unit Components
in Section 7B”.
For automatic type A/C, refer to “HVAC Unit
Components in Section 7B”.
HVAC Unit Removal and InstallationS7RS0B7106002
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove cowl top panel from vehicle body referring to “Cowl Top Components in Section 9K”.
4) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
5) Remove instrument panel from vehicle body referring to “Instrument Panel Removal and
Installation in Section 9C”.
6) Remove nuts (3).
7) Remove HVAC unit from vehicle body.
Installation
Reverse removal procedure noting the following
instructions.
• Be careful not to catch any cable and wiring harness in inappropriate position.
• Adjust control cables of HVAC control unit referring to “HVAC Control Unit Remo val and Installation”.
• Fill engine coolant to radiator.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor Removal and InstallationS7RS0B7106003
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Disconnect connector (1) from blower motor (2).
4) Remove blower motor from HVAC unit by removing screws (3).
Installation
Reverse removal procedure noting the following
instruction.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor InspectionS7RS0B7106004
• Check for continuity between two terminals as shown. If there is no continuity, replace blower motor.
3
2
3
1
3I4RS0B710004-01
3
1
2
3
3
I4RS0B710005-01
I4RS0A710006-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-7
Diagnostic Information and Procedures
A/C System Symptom DiagnosisS7RS0B7214001
ConditionPossible cause Correction / Reference Item
No cool air comes out (A/
C system does not
operate) No refrigerant
Perform recovery, evacuation and charge
referring to “Operation Procedure for
Refrigerant Charge”.
Fuse blown Check related fuses, and then check for short
circuit to ground.
A/C switch faulty Check A/C switch referring to “A/C Switch
Inspection”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection in Section
7A”.
Evaporator thermistor (Evaporator
temperature sensor) faulty Check evaporator thermistor (evaporator
temperature sensor) referring to “Evaporator
Thermistor (Evaporator Temperature Sensor)
Inspection”.
A/C refrigerant pressure sensor faulty Check A/C refrigerant pressure sensor
referring to “A/C Refrigerant Pressure Sensor
and Its Circuit Inspection”.
Wiring or grounding faulty Repair as necessary.
ECM faulty Check ECM referring to “A/C System
Inspection at ECM”.
Magnet clutch faulty Check magnet clutch referring to “Magnet
Clutch Inspection”.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Compressor relay faulty Check compressor relay referring to
“Compressor Relay Inspection”.
BCM faulty Check BCM referring to “Inspection of BCM
and its Circuits in Section 10B”.
No cool air comes out
(radiator cooling fan
motor does not operate) Fuse blown
Check related fuses, and then check for short
circuit to ground.
Wiring or grounding faulty Repair as necessary.
Radiator cooling fan motor relay faulty Check radiator cooling fan motor relay
referring to “Radiator Cooling Fan Relay
Inspection in Section 1F”.
Radiator cooling fan motor faulty Check radiator cooling fan motor referring to
“Radiator Cooling Fan Removal and
Installation in Section 1F”.
ECM and/or its circuit faulty Check ECM and/or its circuit referring to “A/C
System Inspection at ECM”.
No cool air comes out
(blower motor does not
operate) Fuse blown
Check related fuses, and then check for short
circuit to ground.
Blower motor relay faulty Check blower motor relay referring to “Blower
Motor Relay Inspection in Section 7A”.
Blower motor resistor faulty Check blower motor resistor referring to
“Blower Motor Resistor Inspection in Section
7A”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection in Section
7A”.
Wiring or grounding faulty Repair as necessary.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.

Downloaded from www.Manualslib.com manuals search engine 7B-8 Air Conditioning System: Manual Type
Cool air does not come
out or insufficient cooling
(A/C system normal
operation)Insufficient or excessive charge of
refrigerant
Check the amount of refrigerant and system
for leaks.
Condenser clogged Check condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
A/C evaporator clogged or frosted Check A/C evaporator and evaporator
thermistor (evaporator temperature sensor)
referring to “Evaporator Inspection” and
“Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Evaporator thermistor (Evaporator
temperature sensor) faulty Check evaporator thermistor (Evaporator
temperature sensor) referring to “Evaporator
Thermistor (Evaporator Temperature Sensor)
Inspection”.
Expansion valve faulty Check expansion valve referring to “Expansion
Valve Inspection”.
Desiccant clogged Replace receiver/dryer.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Magnet clutch faulty Check magnet clutch referring to “Magnet
Clutch Inspection”.
Compressor faulty Check compressor.
Air in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Air leaking from HVAC unit or air duct Repair as necessary.
Heater and ventilation system faulty Check HVAC unit.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.
Excessive compressor oil in A/C system Drain excessive compressor oil from A/C
system circuit and compressor.
Cool air does not come
out only intermittently Wiring connection faulty
Repair as necessary.
Expansion valve faulty Check expansion valve referring to “Expansion
Valve Inspection”.
Excessive moisture in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Magnet clutch faulty Check magnet clutch referring to “Magnet
Clutch Inspection”.
Excessive amount of refrigerant Check the amount of refrigerant.
Cool air comes out only
when driving vehicle at
high speed Condenser clogged
Check condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
Insufficient charge of refrigerant Check the amount of refrigerant and system
for leaks.
Air in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Cool air does not come
out only when driving
vehicle at high speed Excessive amount of refrigerant
Check the amount of refrigerant.
A/C evaporator frosted Check A/C evaporator and evaporator
thermistor (evaporator temperature sensor)
referring to “Evaporator Inspection” and
“Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-9
Abnormal Noise Symptom Diagnosis of A/C SystemS7RS0B7214002
Abnormal Noise from Compressor
Abnormal Noise from Magnetic Clutch
Abnormal Noise from Tubing
Abnormal Noise from Condenser Assembly
Abnormal Noise from Crankshaft PulleyInsufficient airflow of
cooled air
A/C evaporator clogged or frosted
Check A/C evaporator and evaporator
thermistor (evaporator temperature sensor)
referring to “Evaporator Inspection” and
“Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Air leaking from HVAC unit or air duct Repair as necessary.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.
Wiring or grounding faulty Repair as necessary.
Condition Possible cause Correction / Reference Item
Condition
Possible cause Correction / Reference Item
During compressor
operation, a rumbling
noise is heard
proportional to engine
revolutions Inadequate clearance in scroll area
Replace compressor.
A loud noise is heard at a
certain rpm,
disproportionately to
engine revolution Loose or faulty compressor drive belt
Adjust drive belt tension or replace drive belt.
Loose compressor mounting bolts Retighten mounting bolts.
A loud rattle is heard at
low engine rpm Loose compressor clutch plate bolt
Retighten clutch plate bolt.
Replace compressor if it was operated in this
condition for a long time.
Condition Possible cause Correction / Reference Item
A rumbling noise is heard
when compressor is not
in operation Worn or damaged bearings
Replace magnet clutch assembly.
A chattering noise is
heard when compressor
is in operation Faulty magnet clutch clearance
(excessive clearance)
Adjust magnet clutch clearance.
Worn magnet clutch friction surface Replace magnet clutch assembly.
Compressor oil leaked from shaft seal,
contaminating the friction surface Replace compressor body assembly.
Condition
Possible cause Correction / Reference Item
A droning noise is heard
from inside of the vehicle,
but not particularly
noticeable in engine
compartment Faulty tubing clamps
Reposition clamps or increase the number of
clamps.
Resonance caused by pulsation from
variations in re frigerant pressure Attach a silencer to tubing, or modify its
position and length.
Condition
Possible cause Correction / Reference Item
Considerable vibration in
condenser assembly Resonance from condenser assembly
bracket and body Firmly insert a silenc
er between condenser
assembly bracket and body.
Condition Possible cause Correction / Reference Item
A large rattling noise is
heard at idle or sudden
acceleration Loosen crankshaft pulley bolt
Retighten bolt.